Food Automation ENGINEERED FOR EXCELLENCE IN MACHINERY TECHNOLOGY DRIVING PRODUCTIVITY 30% UPLIFT IN PRODUCTIVITY MARCO - TECHNOLOGY DRIVING PRODUCTIVITY Marco, known throughout the world for providing the very best technology solutions for manufacturing and packing operations, RAPID using the unique Marco Trac-IT MES software and high quality Marco - designed and RETURN manufactured hardware. ON INVESTMENT Marco are the market leaders in providing solutions for high speed manual packing applications. These solutions ensure minimum wastage, virtual eradication of over-pack, individual operator monitoring and offer a guaranteed rapid return on investment. WHY CHOOSE MARCO? Marco design, manufacture, and maintain every system installed globally. This means that their customers only deal with one company which ensures absolute control over quality, delivery times and performance. Each Marco module can be integrated within an existing structure or installed as part of a complete factory-wide system. THE RESULTS: The average improvement in productivity is 30% In 98% of cases, full return on investment is achieved within 12 months MARCO TRAC-IT YIELD CONTROL MODULE (YCM) A HIGHLY ACCURATE SYSTEM THAT VIRTUALLY ERADICATES PRODUCT OVER PACK, REDUCES WASTE AND IMPROVES PRODUCTIVITY WHILST VIRTUAL ALLOWING YOU TO MEASURE, CONTROL AND ELIMINATION IMPROVE THE PACKING PROCESS. OF OVERPACK Each operator has their own ID logon or RFID tag, ensuring that productivity data is individually “Our operators have logged. A simple-to-operate but technically found the new system sophisticated traffic light system guides them as extremely easy to use they work, ensuring target weights and technical and we are now seeing standards are consistently achieved. significant benefits in Marco Trac-IT YCM generates wide-ranging and terms of reduced give immediately traceable packing data including: away.” GREENCORE The number of packs completed over time/per operator The total quantity of produce allocated to each line The actual amount of saleable product packed at each workstation/line The total amount of waste generated at each workstation/Line Pack weight trends by operator/ team/line/factory Yield/mass balance data by batch run/total production A sophisticated performance rating by operator/team/line/factory. MARCO TRAC-IT RECIPE FORMULATION MODULE (RFM) AN INNOVATIVE ELECTRONIC SYSTEM “Marco’s Trac-IT WHICH ACCURATELY, CONSISTENTLY has given us an AND COMPLETELY MANAGES ALL YOUR environment where RECIPE FORMULATION PROCESSES. we now have total control, total visibility, Marco Trac-IT RFM cuts out the need to less mistakes and rely on time-consuming paperwork to one where every manage formulation procedures, providing action is logged. This easy-to-follow, language transparent operational clarity has graphics (Green = Go / Red = No) and enabled us to reduce touch screen prompts to guide operators our raw material stock through the entire process. It ensures holding levels” every ingredient is correctly weighed and UNILEVER collated to give perfect end-products each and every time. MARCO TRAC-IT LINE CONTROL MODULE (LCM) AN AUTOMATED INSPECTION SYSTEM WHICH ENSURES ALL PRODUCTS ARE CORRECTLY PACKAGED, LABELLED AND DATE/LOT CODED. Food retailers and their customers are demanding an increasingly high level of labelling on products and accuracy is paramount. Failure to meet standards can be damaging to your company, disrupting production, forcing costly return-to- manufacturer situations or emergency product withdrawals which inevitably dents customer confidence. Marco’s innovative Line Control Module takes away that enormous headache for you, complying with the most recent retailers’ codes of practice and monitoring 100% of your production 100% of the time. “We recognise that this is a highly competitive market and innovative solutions such as the Marco LCM system will help play an essential part in this, giving us peace of mind that only correctly labelled products can leave our plant.” RHOKETT MARCO TRAC-IT AVERAGE WEIGHT MODULE (AWM) A HIGH PRECISION OFF-LINE WEIGHING “Marco took the SYSTEM WHICH ENSURES FULL time to listen to COMPLIANCE WITH THE LATEST our requirements WEIGHT PACKING LEGISLATION. and understand our processes. They Marco Trac-IT AWM is an efficient means designed the whole of minimising over-filling or over-pack by system around our operators or filling machines, which quickly criteria without any eats into your profits. It can be used with any compromises. During type of pre-packaged goods, from manually the installation their packed fresh produce through to high speed engineers worked automated filling of cans, bottles and cartons. around the clock so that there was minimum Innovative software ensures you will disruption to our consistently meet relevant legislation. normal production.” All the data is stored electronically so you can provide full proof of compliance at the touch GREENCORE of a button. MARCO TRAC-IT MANUFACTURING EXECUTION SYSTEM (MES) A DYNAMIC MANUFACTURING CONTROL “Marco’s Trac-IT has SYSTEM WHICH EXPERTLY JOINS THE become the life blood DOTS AND COORDINATES PRODUCTION of our production PROCESSES FROM GOODS IN RIGHT processes. Its future THROUGH TO GOODS OUT. proof connectivity has been clearly Real-time control is vital to the smooth demonstrated with this running of manufacturing, unlocking second phase and as the potential of your chosen enterprise we grow our business resource planning tool (ERP) and improving we know Trac-IT will be productivity. there to help.” Marco Trac-IT MES is an off-the-shelf BEACON FOODS solution. With over 100,000 man hours of development, it challenges the belief that such systems are complex, costly and time consuming to integrate. It can become part of your existing plant with minimum disruption, bringing immediate improvements to efficiency, product consistency and quality. CASE STUDY: GREENCORE THE COMPANY Greencore Group plc is a leading international manufacturer of convenience foods. They supply a wide range of chilled, frozen and ambient foods to some of the most successful retail and food service customers in the UK and US. Greencore is a world leader in the production of pre-packed sandwiches and other Food To Go products, supplying its customers with more than 500m items each year. THE CHALLENGE Although there are high levels of automation, critical parts of the sandwich process will always rely on manual packing, with the inherent risk of overfill and its obvious cost and technical specification implications. Before Marco’s involvement, there was no real-time visibility of the lines and production data was generated too slowly to be able to take effective action. THE MARCO SOLUTION The installation of fully-wireless Marco Trac-IT Yield Control Modules, made up multiple LineMaster portion-control workstations across 6 Greencore sites. Guided by a simple red-amber-green traffic light system, operators remove the required amount of any sandwich component from trays placed on the weighing platform. EXCELLENT RESULTS Following installation and due to the simplicity of the system only minimal training was required and the operators found the system extremely easy to use All sites now have comprehensive control of their sandwich assembly process and give away has been reduced to a minimum. MARCO CREDENTIALS Marco systems are fully certified and comply to the differing weights and measures standards applied across the globe. This means that you can legally declare the weights of packed produce, secure in the knowledge that this will be accepted by your trading partners and your local authorities - no matter where you are in the world. MARCOS CERTIFICATIONS ARE AS FOLLOWS: NTEP for the USA NAWI for Europe CSA for Canada OIML R76 for Europe, South America and Africa NMI S720 for Australia IND/13/16/363 for India OIML R76/2006-GB1 for New Zealand OUR CLIENTS MARCO’S CUSTOMERS INCLUDE: 2 Sisters Food Group Melton Foods Adelie Foods Group Montana Bakeries AG Barr Mucci Farms Agricola Don Ricardo NatureSweet Backyard Farms Nestle Bakkavor New York Bakery Co Beacon Foods North Bay Produce Capespan Oscar Mayer Cott Beverages Pizza Express Danone Premier Foods Flavourfresh Rougeline Greencore Samworth Brothers Greggs Sociedad Agricola Santa Ana Grupo Alta Solway Foods Grupo Siesa Southern Farms Houweling’s Tomatoes Sundrop International Flavors & Fragrances Sunset Mastronardi International Herbs Unilever McVitie’s Windset Farms MARCO LIMITED FOOD AUTOMATION PTY LTD Enterprise Way PO Box 3242 Edenbridge Newton Kent TN8 6HF South Australia 5074 United Kingdom Australia t +44 (0) 1732 782380 t +61 427 565 658 e [email protected] e [email protected] www.marco.co.uk www.foodautomation.com.au.